System and method for reducing setting loads

Abstract

Embodiments include an energizing ring for setting a downhole seal includes a body having a varied cross-section along at least a portion of an axial length. The energizing ring also includes a plurality of peaks forming at least a portion of the varied cross-section having a first diameter. The energizing ring also includes a plurality of valleys forming at least a portion of the varied cross-section having a second diameter, the first diameter being larger than the second diameter, and respective valleys of the plurality of valleys being arranged proximate respective peaks of the plurality of peaks.

The invention claimed is: 
     
       1. An energizing ring for setting a downhole seal, comprising:
 a body having a varied cross-section along at least a portion of an axial length, the varied cross-section being symmetrical about an axis of the body; 
 a plurality of peaks forming at least a portion of the varied cross-section having a first diameter, each peak of the plurality of peaks being at the first diameter; and 
 a plurality of valleys forming at least a portion of the varied cross-section having a second diameter, each valley of the plurality of valleys being at the second diameter, the first diameter being larger than the second diameter, and respective valleys of the plurality of valleys being arranged proximate respective peaks of the plurality of peaks. 
 
     
     
       2. The energizing ring of  claim 1 , wherein the respective valleys of the plurality of valleys are arranged between pairs of peaks of the plurality of peaks. 
     
     
       3. The energizing ring of  claim 1 , wherein a peak of the plurality of peaks is formed by a tapered section extending radially inward toward an axis of the energizing ring. 
     
     
       4. The energizing ring of  claim 1 , wherein a peak of the plurality of peaks is formed by a bump having a curved edge. 
     
     
       5. The energizing ring of  claim 1 , wherein the energizing ring is arranged within an opening of a seal, the energizing ring being positioned within the seal such that a peak of the plurality of peaks is in contact with the seal and a valley of the plurality of valleys is not in contact with the seal. 
     
     
       6. The energizing ring of  claim 5 , wherein contact between the peak and the seal forms a point of interference, the point of interference corresponding to a location where a frictional force between the energizing ring and the seal opposes movement of the energizing ring in a first direction, opposite a second direction of a setting load. 
     
     
       7. A system for forming a seal between downhole components, the system comprising:
 a seal arranged between at least two downhole components, the seal comprising a first leg and a second leg, each leg positioned proximate one of the at least two downhole components, wherein the first and second legs engage the at least two downhole components upon activation of the seal; 
 an energizing ring to activate the seal, the energizing ring extending into an opening of the seal to drive the first leg and the second leg radially outward relative to an axis of the energizing ring, the energizing ring comprising a plurality of geometric features, forming a varied cross-section, that sequentially contact the seal when the energizing ring is installed within the opening, wherein respective geometric features of the plurality of geometric features form areas of high and low concentrations of pressure that alternate axially along a length of the energizing ring when installed within the opening; 
 a setting tool for driving the energizing ring into the opening of the seal; and 
 a pressure control device for directing a wellbore pressure toward the energizing ring to drive the energizing ring into the opening of the seal; 
 wherein the wellbore pressure is configured to exceed a setting pressure to enable the energizing ring to apply a compression preload to the seal and to overcome frictional forces between the seal and the energizing ring. 
 
     
     
       8. The system of  claim 7 , wherein the plurality of geometric features comprise bumps, flats, tapers, or a combination thereof. 
     
     
       9. The system of  claim 7 , wherein the plurality of geometric features comprises a sequential line of bumps arranged along at least a portion of the energizing ring. 
     
     
       10. The system of  claim 7 , wherein the plurality of geometric features form a plurality of crests at a first diameter and a plurality of valleys at a second diameter, wherein the first diameter is larger than the second diameter. 
     
     
       11. The system of  claim 7 , wherein the plurality of geometric features comprise a first taper extending radially inward to a first diameter, a first flat extending axially at the first diameter, and a second taper extending radially inward to a second diameter, the second diameter being less than the first diameter. 
     
     
       12. The system of  claim 11 , wherein the first flat includes a plurality of bumps, the bumps forming peaks at a third diameter and valleys, arranged between the peaks, at the first diameter, the third diameter being larger than the first diameter. 
     
     
       13. The system of  claim 7 , wherein the frictional forces between the seal and the energizing ring are a function of a contact area between the geometric features and the seal. 
     
     
       14. The system of  claim 7 , wherein the compression preload is a pre-determined value. 
     
     
       15. The system of  claim 7 , wherein the seal and the energizing ring are both made from a metal. 
     
     
       16. The system of  claim 7 , wherein the energizing ring plastically deforms the seal when the energizing ring activates the seal. 
     
     
       17. A method for setting a downhole seal, comprising:
 arranging a seal within a wellbore between at least two wellbore components; 
 aligning an energizing ring with an opening of the seal; 
 driving the energizing ring into the opening of the seal to deform the seal; and 
 engaging legs of the seal with a plurality of geometric features formed symmetrically on the energizing ring, the geometric features having alternating first and second diameters, the first diameters contacting the seal as the energizing ring transitions into the opening, reducing a contact area between the legs and the energizing ring. 
 
     
     
       18. The method of  claim 17 , wherein the energizing ring is driven into the opening of the seal via wellbore pressure. 
     
     
       19. The method of  claim 17 , wherein the geometric features comprise a plurality of peaks and valleys, the peaks being at the first diameter and the valleys being at the second diameter, the method further comprising:
 sequentially contacting the legs with only the peaks as the energizing ring is driven into the opening of the seal; and 
 maintaining a space between the valleys and the legs.